Roof tiles and related systems

ABSTRACT

Roof tile systems for structures are provided. A representative system including solar panel tile having a top side for facing away from a structure, a bottom side for facing the structure, a left side, a right side, an upper side for facing the upslope direction and lower side for facing the downslope direction, the solar panel tile defining a cavity sized and shaped for mounting therein a solar panel, the solar panel tile having a first rib extending across the cavity; and a solar panel mounted within the cavity and supported by the first rib such that the solar panel is flush mounted with respect to the top side of the solar panel tile; the solar panel tile being a first of multiple solar panel tiles, with the multiple tiles being operative to engage in a side-by-side arrangement to form at least a partial course of tiles of the system.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/992,829, filed on 2013 Jul. 15, now issued as U.S. Pat. No. 8,713,861on 2014 May 6, which is a 371 National Phase Application ofPCT/US11/63244, filed on 2011 Dec. 5, which claims the benefit of U.S.Provisional Application No. 61/421,862, filed on 2010 Dec. 10. All ofthese applications are incorporated herein by reference in theirentireties as if expressly set forth herein.

BACKGROUND

1. Technical Field

This disclosure relates to tiled roofing systems.

2. Description of the Related Art

Conventional tiled roofing systems are known that have met with varyingdegrees of success. However, these systems do little to address manymodern needs associated with responsible energy usage and acquisition.

SUMMARY

Roof tiles and related systems are provided. In this regard, anexemplary embodiment of a roof tile system comprises: a solar panel tilehaving a top side for facing away from a structure, a bottom side forfacing the structure, a left side, a right side, an upper side forfacing the upslope direction and a lower side for facing the downslopedirection, the solar panel tile defining a cavity sized and shaped formounting therein a solar panel, the solar panel tile having a first ribextending across the cavity; and a solar panel mounted within the cavityand supported by the first rib such that the solar panel is flushmounted with respect to the top side of the solar panel tile; the solarpanel tile being a first of multiple solar panel tiles, with themultiple tiles being operative to engage in a side-by-side arrangementto form at least a partial course of tiles of the system.

Another exemplary embodiment of a roof tile system comprises: a leftedge tile having a top side for facing away from a structure, a bottomside for facing the structure, a left side, a right side, an upper sidefor facing an upslope direction and a lower side for facing a downslopedirection, the left edge tile further having a left side extendedportion spanning along a length of the left side of the left edge tileand extending from the top side, passed the bottom side and to adistance beyond the bottom side of the left edge tile; a field tilehaving a top side for facing away from a structure, a bottom side forfacing the structure, a left side, a right side, an upper side forfacing the upslope direction and a lower side for facing the downslopedirection; a solar panel tile having a top side for facing away from astructure, a bottom side for facing the structure, a left side, a rightside, an upper side for facing the upslope direction and a lower sidefor facing the downslope direction, the solar panel tile defining acavity sized and shaped for mounting therein a solar panel; and a rightedge tile having a top side for facing away from a structure, a bottomside for facing the structure, a left side, a right side, an upper sidefor facing the upslope direction and a lower side for facing thedownslope direction, the right edge tile further having a right sideextended portion spanning along a length of the right side of the rightedge tile and extending from the top side, passed the bottom side and toa distance beyond the bottom side of the right edge tile; the left edgetile, the field tile, the solar panel tile and the right edge tile beingoperative to engage in a side-by-side arrangement to form at least apartial course of tiles of the system in which at least one of the tilesat least partially overlaps an adjacent one of the tiles.

Other systems, methods, features and/or advantages of this disclosurewill be or may become apparent to one with skill in the art uponexamination of the following drawings and detailed description. It isintended that all such additional systems, methods, features and/oradvantages be included within this description and be within the scopeof the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the disclosure can be better understood with referenceto the following drawings. The components in the drawings are notnecessarily to scale. Moreover, in the drawings, like reference numeralsdesignate corresponding parts throughout the several views.

FIG. 1 is a perspective view of an exemplary embodiment of a roofsystem.

FIG. 2 is a perspective, top view of an exemplary embodiment of a solarpanel tile.

FIG. 3 is a perspective, bottom view of the solar panel tile of FIG. 2.

FIG. 4 is a partially-exploded view of the solar panel tile of FIG. 2.

FIG. 5 is a perspective, top view of an exemplary embodiment of a fieldtile.

FIG. 6 is a perspective, bottom view of the field tile of FIG. 5.

FIG. 7 is a perspective, top view of an exemplary embodiment of a rightedge tile.

FIG. 8 is a perspective, bottom view of the right edge tile of FIG. 7.

FIG. 9 is a perspective, top view of an exemplary embodiment of apartial tile.

FIG. 10 is a perspective, bottom view of the partial tile of FIG. 9.

DETAILED DESCRIPTION

Roof tiles and related systems are provided, several exemplaryembodiments of which will be described in detail. In some embodiments, aroof tile system incorporates several different tile configurations thatcan be combined in various arrangements. Such tile configurations caninclude field tiles and solar panel tiles (which, as the name implies,mount solar panels). Additionally, right edge tiles and left edge tilesthat are designed for trimming out the right and left sides,respectively, of an assembly of tiles can be provided. Notably, in someembodiments, the tiles are formed of durable weather-resistant materialsand can be colored and/or textured to reduce surface temperature, whichcan have a detrimental effect on solar panels.

Referring in more detail to the drawings, FIG. 1 is a perspective viewof an exemplary embodiment of a roof system. As shown in FIG. 1, rooftile system 100 incorporates five types of tiles: a solar panel tile(e.g., tile 102), a field tile (e.g., tile 104), a right edge tile(e.g., tile 106), a left edge tile (e.g., tile 108) and a partial tile(e.g., tile 110). The tiles are arranged in a multi-courseconfiguration, with each course being formed of tiles in a side-by-sideconfiguration. In this embodiment, a portion of each lower course isoverlapped by a portion of an upper course of tiles, and as to adjacenttiles within a course, each tile positioned to the right is overlappedby a portion of the corresponding tile positioned to its left.

An exemplary embodiment of a solar panel tile is shown in FIGS. 2 and 3,in which FIG. 2 is a top view of solar panel tile 102 and FIG. 3 is abottom view. As shown, tile 102 includes a top side 121 for facing awayfrom a support structure, a bottom side 122 for facing the structure, aleft side 123, a right side 124, an upper side 125 for facing theupslope direction and a lower side 126 for facing the downslopedirection. Prominently, tile 102 also defines a cavity 128 that is sizedand shaped for mounting therein a solar panel (not shown in FIGS. 2 and3). In the embodiment shown, the cavity is an open cavity located at acentral portion of the top side of the tile, with several ribs spanningacross the open cavity. Specifically, two main ribs 131, 132 span thecavity widthwise, and two main ribs 133, 134 span the cavity lengthwise.Additionally, intersections of the main ribs include platforms, of whichfour are included in this embodiment (e.g., platform 135), that aresized and shaped to receive respective daubs of adhesive for bonding thesolar panel to the tile. Further, a minor rib 136 spans between ribs133, 134 to add rigidity and to facilitate routing of wiring associatedwith the solar panel. This support will help limit the bending of thesolar panel in general and in case of dynamic loads.

Screw holes (137, 138) are provided to facilitate mounting of the tilesto a batten structure. In some embodiments, one or more of the screwholes can be configured an elongated slot to facilitate tile expansionand contraction.

Also shown in FIGS. 2 and 3 is a vent opening 140 positioned along thelower side of the solar panel tile. The vent opening facilitates airflow into a cooling channel 142 formed beneath the solar panel. That is,the tile is designed for cooling and ventilation that gives a superiorfunctioning of the solar panels. Notably, excessive heat reduces theefficiency of solar panels. This opening allows the wind and the air topenetrate under the solar roof tile and between the battens to cool downthe solar panel element. A continuous flow of air will be created inthis way that cools the solar panel temperature in order to enhancegeneration of electric power.

Additionally, the solar panel tile includes a pair of locking pins (144,145) that protrude outwardly from the upper side of the tile. Thelocking pins are sized and shaped to mate with corresponding lockingmembers positioned on the bottom side of tile of an overlying course oftiles. Notably, the tile 102 carries the locking members (146, 147) forengaging the corresponding locking pins of an adjacent tile. Each of thelocking members has an aperture (e.g., aperture 148) formed therein forreceiving a corresponding locking pin. In some embodiments, the apertureis configured as a laterally-oriented, elongated slot. In such anembodiment, the locking pin can exhibit lateral play within the slotwhich accommodates lateral movement of the associated tile.

Notably, on a side of the tile (e.g., on the right side) is a curvedelement 149 that is configured to cover an edge of an adjacent rooftile. As such, in an assembled configuration, adjacent tiles overlapeach other in the sideways direction. This overlap protects theunderlying roof structure from the natural elements such as rain, windand sun.

As shown in FIG. 4, a solar panel 150 is mounted within the cavity andsupported by the ribs. In this embodiment, the solar panel is flushmounted with respect to the top side of the solar panel tile whenmounted. Also shown in FIG. 4 are raised drip barriers 152, 154 that areused to direct water about the surface of the tile to reduce theopportunity for water to flow under a neighboring tile. Once assembled,the drip barriers are positioned under the curved element of an adjacenttile.

In some embodiments, the width and length of a representative tile isdetermined by the size of a broken up solar cell. Broken up cells arehigh performing cells that produce more electric power than full cells.

An exemplary method for securing a solar panel to a tile involves usingbonding material (e.g., polymer or silicone bonding glue). For instance,before placing bonding material, a plasma treatment is applied to thecavity and bonding surfaces to activate the molecules. This processallows the molecules to react better with the bonding material.

In one such process, within 2 minutes after applying plasma, a bondingpaste of approximately 150 grams per solar roof tile is injected on thebonding surfaces of the opening to hold the solar panel. The bondingmaterial is 2 components and is water resistant and also resists extremetemperatures of −40 Celsius (−38 Fahrenheit) freezing and heats up to+85 Celsius (+185 Fahrenheit) this according to German normalization forsolar roof tiles. German normalization is the world standard for solarpanels and solar roof tiles. In other embodiments, various other amountsand/or types of bonding material (e.g., a single component material) canbe used.

Preferably, the bonding is able to expand and shrink under these extremetemperatures. The bonding also preferably resists dynamic concentratedpressures of hail and a human stepping on the solar roof tile and solarpanel.

The solar panels are made to resist the natural elements and occasionalpressures. The top layer of the solar panel is preferably made oflaminated glass that allows light penetration in the best condition toproduce electric power.

FIGS. 5 and 6 depict an exemplary embodiment of a field tile 104, withFIG. 5 being a top view of the tile and FIG. 6 being a bottom view. Asshown, tile 104 includes a top side 221 for facing away from a supportstructure, a bottom side 222 for facing the structure, a left side 223,a right side 224, an upper side 225 for facing the upslope direction anda lower side 226 for facing the downslope direction. Tile 104 alsoincludes a vent opening 230 positioned along the lower side of the tileto facilitate air flow into a cooling channel 232 formed beneath thetile.

Additionally, tile 104 includes a pair of locking pins (234, 235) thatprotrude outwardly from the upper side of the tile. The locking pins aresized and shaped to mate with corresponding locking members positionedon the bottom side of tile of an overlying course of tiles. In someembodiments, the pins are T-shaped and long enough to allow verticalmovement of the roof tiles. Thus, each roof tile can move up or down ortop to bottom under limited measurements. This may be needed whencalculating a roof to determine the number of roof tiles needed from topto bottom. By moving the roof tiles more outward or inward on the pins,cutting of roof tiles can be limited because the tiles are still securedto one another across a range of variable widths and lengths.

Notably, the tile 104 carries the locking members (236, 237) forengaging the corresponding locking pins of an adjacent tile. Each of thelocking members has an aperture (e.g., aperture 238) formed therein forreceiving a corresponding locking pin. In some embodiments, the apertureis configured as a laterally-oriented, elongated slot. In such anembodiment, the locking pin can exhibit lateral play within the slotwhich accommodates lateral movement of the associated tile.

In some embodiments, the characteristics of the pin are also to allowroof tiles to be placed under an angle of 5%. Practical example: thebottom 3 roof tiles are tilted up 5% on the end of a roof structuresometimes done on ranch homes. The T-shaped pin can be partially cut offon the bottom so the roof tiles can end up in an angle and still holdthe roof resistant against the wind. It should be noted that the twotypes of roof tiles previously described, the solar panel tile and thefield tile, can use the same technique of roof tile pins and aperturesas locking systems.

As best shown in FIG. 6, a tile can incorporate a roof tile tape (240)that can be used as an aid to cut roof tiles to desired dimensions.

FIG. 7 is a perspective, top view of an exemplary embodiment of a rightedge tile 106, with FIG. 8 showing the bottom view of the tile. Asshown, tile 106 includes a top side 321 for facing away from a supportstructure, a bottom side 322 for facing the structure, a left side 323,a right side 324, an upper side 325 for facing the upslope direction anda lower side 326 for facing the downslope direction. Tile 106 alsoincludes a vent opening 330 positioned along the lower side of the tileto facilitate air flow into a cooling channel 332 formed beneath thetile. Notably, tile 106 also includes a right side extended portion 333spanning along a length of the right side of the right edge tile, withthe right side exhibiting a cylindrical shape along the top side of thetile. This extended portion extends from the top side, passed the bottomside and to a distance beyond the bottom side of the right edge tile. Soconfigured the right edge tile is adapted to end a course of tiles bybeing the last tile of the course on the right hand side, with theextended portion acting to finish the course by partially covering theside of the batten structure to which the tile is attached in someembodiments.

Additionally, tile 106 includes a pair of locking pins (334, 335) thatprotrude outwardly from the upper side of the tile. The locking pins aresized and shaped to mate with corresponding locking members positionedon the bottom side of tile of an overlying course of tiles. In someembodiments, the pins are T-shaped and long enough to allow verticalmovement of the roof tiles. Thus, each roof tile can move up or down ortop to bottom under limited measurements. This may be needed whencalculating a roof to determine the number of roof tiles needed from topto bottom. By moving the roof tiles more outward or inward on the pins,cutting of roof tiles can be limited because the tiles are still securedto one another across a range of variable widths and lengths.

Notably, the tile 106 carries the locking members (336, 337) forengaging the corresponding locking pins of an adjacent tile. Each of thelocking members has an aperture (e.g., aperture 338) formed therein forreceiving a corresponding locking pin. In some embodiments, the apertureis configured as a laterally-oriented, elongated slot. In such anembodiment, the locking pin can exhibit lateral play within the slotwhich accommodates lateral movement of the associated tile.

A left edge tile (e.g., tile 108) can be configured as a mirror image oftile 106 in some embodiments.

FIG. 9 is a perspective, top view of an exemplary embodiment of apartial tile, with FIG. 10 showing the bottom view of the tile. Asshown, tile 110 includes a top side 421 for facing away from a supportstructure, a bottom side 422 for facing the structure, a left side 423,a right side 424, an upper side 425 for facing the upslope direction anda lower side 426 for facing the downslope direction. Tile 106 alsoincludes a vent opening 430.

Additionally, tile 110 includes a pair of locking pins (434, 435) thatprotrude outwardly from the upper side of the tile and locking members(436, 437) for engaging the corresponding locking pins of an adjacenttile.

In some embodiments, the partial tile has a width that is half the widthof a field tile. Notably, availability of partial tiles can reduce cutthat need to be made onsite for assembling a roof tile system.

Roof tiles can be formed of various materials and by various techniques.In some embodiments, high pressured injection technologies with coloredpolypropylene mixed and strengthened with glass fibers are used.Additionally, the surface of a tile can be is flat with a microscopicstructured surface. This can be configured to reduce sun reflection andprevent excessive surface temperatures. A UV resistant factor can alsobe included with or without a color master badge.

It should be emphasized that the above-described embodiments are merelypossible examples of implementations set forth for a clear understandingof the principles of this disclosure. Many variations and modificationsmay be made to the above-described embodiments without departingsubstantially from the spirit and principles of the disclosure. All suchmodifications and variations are intended to be included herein withinthe scope of this disclosure and protected by the accompanying claims.

1. A tile, comprising: a top to face away from a structure; a bottom toface the structure; a side; an upper end to face an upslope direction; alower end to face a downslope direction; a cavity located at a centralportion of the top, the cavity to mount therein a solar panel; a ribspanning the cavity; and a vent opening for facilitating air flow to thesolar panel.
 2. The tile of claim 1, further comprising: a horizontalrib spanning a width of the cavity; and a vertical rib spanning a lengthof the cavity.
 3. The tile of claim 2, further comprising a platformlocated at the intersection of the horizontal rib and the vertical rib.4. The tile of claim 1, further comprising a screw hole to facilitatemounting of the tile.
 5. The tile of claim 4, the screw hole beinglocated near the upper end.
 6. The tile of claim 1, the vent openingbeing positioned along the lower end.
 7. The tile of claim 1, furthercomprising a locking pin protruding outwardly from the upper end.
 8. Thetile of claim 1, further comprising a locking member located on thebottom.
 9. The tile of claim 8, the locking member comprising alaterally-oriented, elongated slot.
 10. The tile of claim 1, furthercomprising a curved element located on the side.
 11. The tile of claim1, further comprising a drip barrier located on the top.
 12. The tile ofclaim 1, further comprising a cooling channel formed below the solarpanel when the solar panel is mounted in the cavity.